Method of repairing a disk stack

ABSTRACT

A method for repairing a disk stack includes providing a disk stack comprising a plurality of original disks, each of the original disks defining a groove pattern, the disk stack defining a damaged region; removing the damaged region from the disk stack to define an insert opening in the disk stack; providing a disk stack repair insert comprising a replacement disk segment; and inserting the disk stack repair insert into the insert opening to repair the damaged region.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. application Ser. No.16/797,763, filed Feb. 21, 2020, which is hereby specificallyincorporated by reference herein in its entirety.

TECHNICAL FIELD

This disclosure relates to valves. More specifically, this disclosurerelates to a disk stack repair insert for repairing a damaged diskstack.

BACKGROUND

Disk stacks are commonly used with control valves in power plants, suchas coal and nuclear plants, to dissipate pressure and/or heat of steamexiting boilers of the power plant. Disk stacks typically comprise aplurality of disks defining grooves formed therein, which can form fluidpassageways around and between the disks from a center bore through thedisk stack to an outer surface of the disk stack. As steam or otherfluid flows outward through the fluid passageways from the center bore,the pressure and heat of the steam or other fluid can be significantlyreduced due to spreading of the fluid in multiple directions by multiplefluid passageways. Additionally, the fluid passageways can eachindividually define a plurality of turns from within the disk stack tooutside of the disk stack to further assist in lowering and dissipatingpressure and heat. However, fluid entering the disk stack at a highpressure can cause damage to the disk stack. Often, entire disk stacksmust be replaced to ensure proper operation of the disk stack afterdamage has occurred.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended neither to identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

Disclosed is a disk stack repair insert comprising a first replacementdisk segment defining a first groove pattern comprising first grooves;and a second replacement disk segment defining a second groove patterncomprising second grooves, the first replacement disk segment coupled tothe second replacement disk segment, wherein the first groove patternand the second groove pattern define a fluid passageway therebetween.

Also disclosed is a repaired disk stack comprising a disk stackcomprising a plurality of original disks joined together in a stackedconfiguration, a first fluid passageway formed between a pair ofadjacent original disks, an insert opening formed through the diskstack; and a disk stack repair insert positioned in the insert opening,the disk stack repair insert comprising a plurality of replacement disksegments, a second fluid passageway formed between a pair of adjacentreplacement disk segments.

A method for repairing a disk stack is also disclosed, the methodcomprising providing a disk stack comprising a plurality of originaldisks, each of the original disks defining a groove pattern, the diskstack having a damaged region; removing the damaged region from the diskstack to define an insert opening in the disk stack; providing a diskstack repair insert comprising a replacement disk segment; and insertingthe disk stack repair insert into the insert opening to repair thedamaged region.

Various implementations described in the present disclosure may includeadditional systems, methods, features, and advantages, which may notnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure.Corresponding features and components throughout the figures may bedesignated by matching reference characters for the sake of consistencyand clarity.

FIG. 1A is a perspective view of a disk stack, in accordance with oneaspect of the present disclosure.

FIG. 1B is a cross-sectional view of the disk stack of FIG. 1A, takenalong line 1-1 of FIG. 1A, wherein the disk stack is positioned within avalve assembly.

FIG. 2 is a perspective view of a damaged region of the disk stack ofFIG. 1A.

FIG. 3 is a perspective view of the damaged region of FIG. 2 beingremoved from the disk stack of FIG. 1A.

FIG. 4 is a front view of the disk stack of FIG. 1A with the damagedregion of FIG. 2 removed.

FIG. 5 is a perspective view of a primary replacement disk.

FIG. 6 is a perspective view of the primary replacement disk of FIG. 5cut into three primary replacement disk segments.

FIG. 7 is a perspective view illustrating the primary replacement disksegments of FIG. 6 and a plurality of secondary replacement disksegments being assembled into a disk stack repair insert.

FIG. 8 is a perspective view of the disk stack repair insert of FIG. 7in an assembled configuration.

FIG. 9 is a perspective view of the disk stack repair insert of FIG. 7partially engaged with the disk stack of FIG. 1A.

FIG. 10 is a perspective view of the disk stack repair insert of FIG. 7engaged with the disk stack of FIG. 1A to define a repaired disk stack.

FIG. 11 is a front view of the repaired disk stack of FIG. 10, whereinthe disk stack repair insert has been machined to be substantially flushwith the disk stack.

FIG. 12 is a detail view of the repaired disk stack of FIG. 10.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference tothe following detailed description, examples, drawings, and claims, andthe previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this disclosure is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,and, as such, can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of thepresent devices, systems, and/or methods in its best, currently knownaspect. To this end, those skilled in the relevant art will recognizeand appreciate that many changes can be made to the various aspects ofthe present devices, systems, and/or methods described herein, whilestill obtaining the beneficial results of the present disclosure. Itwill also be apparent that some of the desired benefits of the presentdisclosure can be obtained by selecting some of the features of thepresent disclosure without utilizing other features. Accordingly, thosewho work in the art will recognize that many modifications andadaptations to the present disclosure are possible and can even bedesirable in certain circumstances and are a part of the presentdisclosure. Thus, the following description is provided as illustrativeof the principles of the present disclosure and not in limitationthereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “an element” can include two or more suchelements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

For purposes of the current disclosure, a material property or dimensionmeasuring about X or substantially X on a particular measurement scalemeasures within a range between X plus an industry-standard uppertolerance for the specified measurement and X minus an industry-standardlower tolerance for the specified measurement. Because tolerances canvary between different materials, processes and between differentmodels, the tolerance for a particular measurement of a particularcomponent can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list. Further, oneshould note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily include logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular aspect.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutations of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific aspect orcombination of aspects of the disclosed methods.

Disclosed in the present application is a disk stack repair insert for adisk stack and associated methods, systems, devices, and variousapparatus. Example aspects of the disk stack can comprise a plurality ofreplacement disk segments arranged in series and at least one pinextending through the plurality of replacement disk segments. It wouldbe understood by one of skill in the art that the disclosed disk stackrepair insert is described in but a few exemplary aspects among many. Noparticular terminology or description should be considered limiting onthe disclosure or the scope of any claims issuing therefrom.

FIG. 1A illustrates a first aspect of a disk stack 100 according to thepresent disclosure. According to example aspects, the disk stack 100 canbe utilized within a fluid system. For example, the disk stack 100 canbe coupled with a valve (not shown) and can be configured reduce thepressure of a fluid (e.g., a gas such as steam, a liquid such as water,etc) as it flows through fluid passageways 175 formed in the disk stack100, as described in further detail below. As shown, the disk stack 100can comprise a plurality of original disks 110 stacked in series todefine a substantially cylindrical structure. For example, the originaldisks 110 can be stacked in a substantially vertical arrangement,relative to the orientation shown. In some aspects, each of the originaldisks 110 can joined to adjacent original disks 110 by a brazingprocess, for example. Brazing can comprise inserting a filler materialbetween a pair of adjacent original disks 110 and allowing the fillermaterial to cool therebetween, coupling the adjacent original disks 110together. In other aspects, however, adjacent original disks 110 can becoupled together by any other suitable fasteners, such as, for example,welding, bolts, screws, or the like. Furthermore, the disk stack 100 cancomprise a plurality of fastener openings 130 configured to receivefasteners (not shown) for coupling the disk stack 100 to the valve orother element of the fluid system.

Example aspects of the disk stack 100 can define a top end 132 (e.g., aplugged end 102) and a bottom end 134 (e.g., an inlet end 104), relativeto the orientation shown, and can define a height H₁. In the presentaspect, the disk stack 100 can comprise a top disk cap 140 positioned atthe top end 132 thereof, which can define a substantially smooth upperdisk cap surface 142. Furthermore, the disk stack 100 can comprise abottom disk cap 144 positioned at the bottom end 134 thereof, which candefine a substantially smooth lower disk cap surface (not shown). Theplurality of original disks 110 can be stacked between the top disk cap140 and bottom disk cap 144, as shown. According to example aspects,each of the original disks 110 can be substantially flat and can definean upper disk surface 212 (shown in FIG. 2) and a lower disk surface 214(shown in FIG. 2). Each of the original disks 110 can further define asubstantially circular outer edge 116 and a substantially circular inneredge 118. In example aspects, the inner edges 118 of the original disks110 can each define an original disk bore 120 formed through theoriginal disk 110.

As such, when the original disks 110 are arranged in series, as shown,the plurality of original disk bores 120 can define an elongatedvertical disk stack inner bore 150 formed through a center of the diskstack 100 from the top end 132 to the bottom end 134, such that the topend 132 can define an open top end 132 and the bottom end 134 can definean open bottom end 134. As shown, a disk stack axis 152 can extendcentrally through the disk stack inner bore 150. In some aspects, theoriginal disk bores 120 of the original disks 110 can be formedtherethrough before the original disks 110 are assembled together todefine the disk stack 100. However, in other aspects, the original disks110 may not comprise the original disk bores 120 when joined together todefine the disk stack 100, and the disk stack inner bore 150 of the diskstack 100 can be drilled through the assembled original disks 110 of thedisk stack 100.

According to example aspects, the circular inner edges 118 of theoriginal disks 110 can define an inner surface 160 of the disk stack100, as shown. The inner surface 160 can be substantially cylindrical inshape and can define an inner diameter D₁ and an inner circumference ofthe disk stack 100. Furthermore, the circular outer edges 116 of theoriginal disks 110 can define an outer surface 170 of the disk stack100, as shown. The outer surface 170 can be substantially cylindrical inshape and can define an outer diameter D₂ that can be greater than theinner diameter D₁ of the disk stack 100 and an outer circumference thatcan be greater than the inner circumference of the disk stack 100.Furthermore, according to various example aspects, the original disks110 can be formed from a metal material, such as, for example, stainlesssteel. In other aspects, the original disks 110 can comprise any othersuitably durable material known in the art, including, but not limitedto, an Inconel® alloy, such as Inconel® 718, Inconel® 625, or Inconel®440.

According to example aspects, grooves 165 (shown in FIG. 1B) can bemachined into each of the original disks 110, which, when the originaldisks 110 are stacked as shown, can define the fluid passageways 175 inthe disk stack 100. For example, in the present aspect, the grooves 165can define a first groove pattern 620 (shown in FIG. 6) formed on theupper disk surface 212 of each of the original disks 110 and a secondgroove pattern 720 (shown in FIG. 7) formed on the lower disk surface214 of each of the original disks 110. According to various exampleaspects, the first and second groove patterns 620,720 can be formed onthe corresponding original disks 110 by electrical discharge machining(EDM); however, in other aspects, the grooves 165 can be formed by anyother suitable type of machining, including, but not limited to,milling, casting, additive manufacturing (i.e., 3D printing), and thelike. The original disks 100 can be stacked such that the upper disksurface 212 of each original disk 110 abuts the lower disk surface 214of an adjacent original disk 110.

As such, each of the first groove patterns 620 can be configured to abutan adjacent second groove pattern 720 to define one or more of the fluidpassageways 175 therebetween. In the present aspect, a plurality offluid passageways 175 can be formed between adjacent pairs of originaldisks 110. Each of the fluid passageways 175 can extend from the innersurface 160 of the disk stack 100 to the outer surface 170 of the diskstack 100 and can define one or more bends and/or turns, such as, forexample, a series of 90° turns. According to example aspects, fluid canenter the disk stack inner bore 150 through the inlet end 104 of thedisk stack 100. The fluid can then flow into the fluid passageways 175at passageway inlet openings 176 formed at the inner surface 160 of thedisk stack 100 and can flow out of the fluid passageways 175 atpassageway outlet openings 178 at the outer surface 170 of the diskstack 100. In one example aspect of a fluid passageway 175, a firstgroove of the first groove pattern 620 of a first original disk 110 acan define the passageway inlet opening 176 of the fluid passageway 175.Fluid can flow into the first groove of the first original disk 110 aand can be guided around a turn or bend into a second groove of thesecond groove pattern 720 of an adjacent second original disk 110 b. Thefluid can then be guided around another turn or bend into a third grooveof the first groove pattern 620 of the first original disk 110 a, and soon, until the fluid exits the fluid passageway 175 through thecorresponding passageway outlet opening 178. As the fluid is dispersedinto the fluid passageways 175 and moves through series of turns definedtherein, the velocity and pressure of the fluid can be reduced, asdescribed in further detail below.

Referring to FIG. 1B, a valve assembly 180 comprising the disk stack 100can have the disk stack 100 mounted therein, such that one end of thedisk stack 100, such as the inlet end 104 (e.g., the bottom end 134),faces an inlet 184 of the valve assembly 180. The other end of the diskstack 100, such as the plugged end 102 (e.g., the top end 132), can be,in some aspects, plugged with a movable plug 190 that can move throughthe disk stack inner bore 150 to control fluid flow from the inlet 184of the valve assembly into the disk stack 100 to the fluid passageways175 by selectively covering and uncovering the passageway inlet openings176 of the fluid passageways 175 as the plug 190 moves within the diskstack inner bore 150. Fluid can then exit the fluid passageways 175through the passageway outlet openings 178 formed at the outer surface170 of the disk stack 100 to an outlet 182 of the valve assembly 180. Asthe fluid moves through the fluid passageways 175 from the disk stackinner bore 150 to the outer surface 170, both the fluid and its energycan be dissipated such that an exit pressure of the fluid upon exitingthe disk stack 100 can be less than an entrance pressure of the fluidupon entering the disk stack 100. For example, in one aspect, fluid canenter the disk stack 100 at an entrance pressure of about 3000 psi andcan exit the disk stack 100 at an exit pressure between about 250 and300 psi. The lower pressure fluid exiting the disk stack 100 can then besuitable for use in lower pressure applications, thereby protectingdownstream valves and other fluid system infrastructure. In otheraspects, fluid can enter the disk stack 100 at another entrance pressureand can exit at another exit pressure, provided the exit pressure isless than the entrance pressure.

In other example aspects, the grooves 165 and fluid passageways 175 maybe alternatively formed. For example, in a first alternate aspect, someor all of the fluid passageways 175 may defined in a single originaldisk 110, as opposed to being defined between a pair of the adjacentoriginal disks 110, as shown in the present aspect. In other aspects,some or all of the fluid passageways 175 can vary in shape and/orlength. Furthermore, the number of fluid passageways 175 formed in thedisk stack 100 can vary, and the number of fluid passageways 175 mayeven vary between the original disks 110. In still other aspects, notall of the original disks 110 of the disk stack 100 define the grooves165 fluid passageways 175. As such, it can be seen that theconfiguration of fluid passageways can be varied in different aspects ofthe disk stack 100 to provide the desired reduction in velocity andpressure of fluid flowing therethrough.

In some instances, the high entrance pressure of the fluid upon enteringthe disk stack 100 can undesirably damage the disk stack 100. Forexample, FIG. 2 illustrates the disk stack 100 comprising a damagedregion 220 caused by high-pressure and high-temperature fluid. As shown,the damaged region 220 can define a defect 230, such as a hole 232,extending from the inner surface 160 of the disk stack 100 to the outersurface 170 (shown in FIG. 1A). The original disks 110 damaged by thedefect 230 can be considered affected disks 240. In example aspects, thedefect 230 can mar the grooves 165 formed in the original disks 110, andthus can interrupt the fluid passageways 175 and can reduce theeffectiveness of the disk stack 100 at decreasing the pressure of thefluid traveling therethrough, such as by blocking some of the fluidpassageways 175. In other aspects, the defect 230 may not extend fullythrough the disk stack 100 from the inner surface 160 to the outersurface 170, but can still damage the grooves 165 formed in the originaldisks 110 and interrupt the fluid passageways 175 formed by the grooves165. As such, the disk stack 100 must be repaired or replaced tocontinue effective operation.

FIG. 3 illustrates an example method for removing the damaged region 220from the disk stack 100 so that the disk stack 100 can be repaired. Thedamaged region 220 can be removed from the disk stack 100 by firstcutting around the damaged region 220 and then removing the materialwithin the cut. For example, as shown, in one aspect, the cut can beformed by a tool 310, such as, for example, a drill 312. In otheraspects, the cut can be formed by any other suitable cutting methods. Inthe present aspect, the tool 310 can engage the disk stack 100 at theouter surface 170 thereof and can cut fully through the disk stack 100to the inner surface 160 (shown in FIG. 1A). The tool 310 can then bemoved around a periphery of the damaged region 220 to drill anencircling cut 320 entirely around the hole 232 or other defect 230. Forexample, the tool 310 can be manually moved by a human operator or canbe automatically moved by a machine, or can be operated in any othersuitable fashion. As such, the affected disks 240 can comprise anyoriginal disk 110 damaged by the defect 230 and/or that is cut by thedrill 312. The encircling cut 320 can define a removable section 330 ofthe disk stack 100 comprising the entire damaged region 220, which canbe removed from the disk stack 100. For example, the removable section330 can be removed manually, by a machine, or in any other suitablefashion. In some aspects, a clearance can be provided between the hole232 or other defect 230 and the encircling cut 320 to ensure that theentire defect 230, including damage that may not be visible, isencompassed within the removable section 330. In one aspect, damage thatmay not be visible can include, for example, weakened areas of the diskstack 100 surrounding the defect 230. For example, in a particularaspect wherein the hole 232 or other defect 230 can generally define alength of about 4 inches, the removable section 330 can define a lengthof about 8 inches, providing a clearance of about 2 inches on eitherside of the hole 232.

As shown in FIG. 4, an insert opening 410 can be formed in the diskstack 100 where the removable section 330 (shown in FIG. 3) has beenremoved. Example aspects of the insert opening 410 can be defined by apair of opposing boundary sidewalls 412, an upper boundary wall 414, anda lower boundary wall 416, as shown. According to example aspects, theaffected disks 240 can terminate at the boundary sidewalls 412.Optionally, as shown in the present aspect, the encircling cut 320(shown in FIG. 3) can be made such that the boundary sidewalls 412 aresolid and do not intersect any of the grooves 165 (shown in FIG. 1B)formed in the affected disks 240. As shown, in the present aspect, theupper boundary wall 414 can be formed by the top disk cap 140. Moreover,in the present aspect, the lower boundary wall 416 can be formed by theupper disk surface 212 (shown in FIG. 2) of an uppermost one of theoriginal disks 110 c. As such, the lower boundary wall 416 can definethe first groove pattern 620 (shown in FIG. 6). According to exampleaspects, the insert opening 410 can be configured to receive a diskstack repair insert 800 (shown in FIG. 8) therein to repair the diskstack 100 and restore the fluid passageways 175 of the affected disks240 to their original configuration, as will be described in furtherdetail below. In some aspects, as shown, the boundary wall(s) 412 candefine a substantially smooth surface, which can allow for easyinsertion of the disk stack repair insert 800 into the insert opening410 and sealing of disk stack repair insert 800 with the disk stack 100,as will also be described in further detail below.

In some aspects, the size (e.g., length, width, etc.) of the insertopening 410 can be a function of the size of the disk stack 100. Forexample, in the present aspect, the length of the insert opening 410 canbe about ⅓ of the length of the disk stack 100. That is to say, an arclength of the insert opening 410 at the inner surface 160 of the diskstack 100 can be about ⅓ of the inner circumference of the disk stack100. Furthermore, an arc length of the insert opening 410 at the outersurface 170 of the disk stack 100 can be about ⅓ of the outercircumference of the disk stack 100. Moreover, in the present aspect, aheight H₂ of the insert opening 410 can be about ⅙ of the height H₁(shown in FIG. 1A) of the disk stack 100. For example, in one aspect,the disk stack 100 can comprise thirty six original disks 110, six ofwhich can be affected disks 240. The height H₂ of the insert opening 410can span the six affected disks 240. As such, aspects wherein the sizeof the insert opening 410 is a function of the size of the disk stack100 can make it easy to determine the size the disk stack repair insert800 needed to fit seamlessly within the insert opening 410. However, inother aspects, the size of the insert opening 410 may not be a functionof the size of the disk stack 100, and the dimensions of the insertopening 410 can simply be measured to determine the size of the diskstack repair insert 800 needed.

FIG. 5 illustrates an example aspect of a replacement disk, for example,a primary replacement disk 510. Similar to the original disks 110 (shownin FIG. 1A), example aspects of the primary replacement disk 510 candefine a lower replacement disk surface 714 (shown in FIG. 7) and anupper replacement disk surface 512. The primary replacement disk 510 canfurther define a substantially circular cross-sectional shape and areplacement disk bore 516 formed through a center thereof. In exampleaspects, the primary replacement disk 510 can be formed from a metalmaterial, such as, for example, stainless steel. However, in otheraspects, the primary replacement disk 510 can be formed from any othersuitably durable material. Furthermore, in some aspects, the primaryreplacement disk 510 can be formed from the same material as theoriginal disks 110 of the disk stack 100 (shown in FIG. 1A), while inother aspects, the primary replacement disk 510 can be formed from adifferent material. As shown, example aspects of the primary replacementdisk 510 can define a primary replacement disk outer diameter D₄ and aprimary replacement disk outer circumference that can be larger than theouter diameter D₂ and outer circumference of the disk stack 100,respectively. The primary replacement disk 510 can also define a primaryreplacement disk inner diameter D₃ and a primary replacement disk innercircumference that can be smaller than the inner diameter D₁ and innercircumference of the disk stack 100, respectively. In other aspectshowever, the primary replacement disk inner and outer diameters D₃,D₄and circumference can be about equal to the inner and outer diametersD₁,D₂ and circumference of the disk stack 100, respectively.

As shown in FIG. 6, the grooves 165 can be machined into the primaryreplacement disk 510 in the same manner that the grooves 165 weremachined into the original disks 110 (shown in FIG. 1A), for example, byelectrical discharge machining. For example, in the present aspect, thefirst groove pattern 620 can be machined into the upper replacement disksurface 512 and the second groove pattern 720 (shown in FIG. 7) can bemachined into the lower replacement disk surface 714 (shown in FIG. 7).As such, the grooves 165 formed in the primary replacement disk(s) 510can match the grooves 165 formed in the original disks 110 of the diskstack 100 (shown in FIG. 1A). That is to say, in the present aspect, thefirst groove pattern 620 formed in the upper replacement disk surface512 of the primary replacement disk 510 can match the first groovepattern 620 formed in the upper disk surface 212 (shown in FIG. 2) ofeach original disk 110, and the second groove pattern 720 formed in thelower replacement disk surface 714 of the primary replacement disk 510can match the second groove pattern 720 formed in the lower disk surface214 (shown in FIG. 2) of each original disk 110. In other aspects, theprimary replacement disk 510 can define any other suitable groovepattern, and may or may not be configured to match the grooves 165formed in the original disks 110.

Furthermore, as shown, the primary replacement disk 510 can be sectionedinto a plurality of primary replacement disk segments 612. For example,in the present aspect, because the length of the insert opening 410(shown in FIG. 4) in the disk stack 100 is about ⅓ the length of thedisk stack 100, the primary replacement disk 510 can be sectioned intothirds, i.e., into three primary replacement disk segments 612. As such,each of the primary replacement disk segments 612 can be dimensionedlengthwise to fit seamlessly within the insert opening 410, as will bedescribed in further detail below. However, in other aspects, theprimary replacement disk 510 can be sectioned into more or fewer primaryreplacement disk segments 612 as needed, depending upon the size of theinsert opening 410 within which the primary replacement disk segments612 will be received. According to the present aspect, the three primaryreplacement disk segments 612 can be configured to fix three of theaffected disks 240 (shown in FIG. 2).

Moreover, the primary replacement disk 510 can be sectioned into theprimary replacement disk segments 612 at locations that do not intersectthe grooves 165 formed in the primary replacement disk 510. As such, asshown, a pair of opposing edges 614 a,b of each of the primaryreplacement disk segments 612 can be configured such that they are solidand do not intersect the grooves 165 formed therein. That is to say, thefirst groove pattern 620 formed in the upper replacement disk surface512 and the second groove pattern 720 (shown in FIG. 7) formed in thelower replacement disk surface 714 (shown in FIG. 7) of each of theprimary replacement disk segments 612 do not intersect with, andtherefore are not interrupted by, the opposing edges 614 a,b of thecorresponding primary replacement disk segment 612. Furthermore, asdescribed above, the boundary sidewalls 412 (shown in FIG. 4) of theinsert opening 410 (shown in FIG. 4) can be configured such that they donot intersect any of the grooves 165 formed in the affected disks 240(shown in FIG. 2). This configuration can eliminate the difficulty ofhaving to align grooves 165 at the edges 614 a,b of the replacementdisks 612 with grooves 165 at the boundary sidewalls 412. In otheraspects, however, there may not be a primary replacement disk 510 thatis sectioned into the primary replacement disk segments 612; rather,each of the primary replacement disk segments 612 can be formedindependently from one another by any suitable manufacturing process,including, but not limited to, casting, 3D printing, and the like.

Moreover, according to example aspects, one or more alignment holes 630can be formed through each of the three primary replacement disksegments 612, as shown. For example, in the present aspect, each of theprimary replacement disk segments 612 can comprise five alignment holes630 a—e equally spaced apart generally along an arcuate centerline 640of the corresponding primary replacement disk segment 612. However,other aspects of the primary replacement disk segments 612 can definemore or fewer alignment holes 630 therethrough. Furthermore, in otheraspects, some or all of the alignment holes 630 may not be oriented atthe arcuate centerline 640 of the corresponding primary replacement disksegment 612 and/or may not be equally spaced.

Referring to FIG. 7, as shown, a secondary replacement disk 710 can alsobe provided. The secondary replacement disk 710 can be substantiallysimilar to the primary replacement disk 510, defining the first groovepattern 620 (shown in FIG. 6) on the upper replacement disk surface 512thereof and defining the second groove pattern 720 on the lowerreplacement disk surface 714 thereof. As such, the grooves 165 of thesecondary replacement disk 710 can match the grooves 165 of eachoriginal disk 110. As shown, the secondary replacement disk 710 can besectioned into three secondary replacement disk segments 712, and eachof the secondary replacement disk segments 712 can define the alignmentholes 630 arranged in the same manner as the alignment holes 630 of theprimary replacement disk segments 612. The plurality of primaryreplacement disk segments 612 and secondary replacement disk segments712 can be stacked in series and joined together to form the disk stackrepair insert 800 (shown in FIG. 8).

According to example aspects, the primary replacement disk segments 612and secondary replacement disk segments 712 can be stacked in the samearrangement as the original disks 110 of the disk stack 100, whereineach of the upper replacement disk surfaces 512 defining the firstgroove pattern 620 can abut a lower replacement disk surface 714defining the second groove pattern 720 of an adjacent primary orsecondary replacement disk segment 612,712. As such, in thisconfiguration, the stacking arrangement of the disk stack repair insert800 (shown in FIG. 8) can be configured to correspond with the stackingarrangement of the disk stack 100 (shown in FIG. 1A), and the fluidpassageways 175 can be defined between the adjacent pairs of replacementdisk segments 612,712 as described above. In the present aspect, thethree primary replacement disk segments 612 can be stacked togetherfirst, followed by the three secondary replacement disk segments 712. Inother aspects, the primary and secondary replacement disk segments canbe stacked together in any other suitable configuration. Furthermore, asmany replacement disk segments as needed can be stacked together toreplicate the removable section 330 (shown in FIG. 3) that has beenremoved from the disk stack 100, such that the resulting disk stackrepair insert 800 can fit seamlessly within the insert opening 410(shown in FIG. 4).

According to example aspects, when stacked in configuration describedabove, the alignment holes 630 of each primary and secondary replacementdisk segment 612,712 can align with the corresponding alignment holes630 of the other primary and secondary replacement disk segments612,712. For example, all of the alignment holes 630 a can be inalignment, all of the alignment holes 630 b can be in alignment, and soon. Moreover, according to example aspects, an alignment pin 730 can bereceived through each set of corresponding alignment holes 630 toproperly orient the primary and secondary replacement disk segments612,712 in the stacked configuration. In some aspects, the alignmentpins 730 can be inserted through the corresponding alignment holes 630as the primary and secondary replacement disk segments 612,712 are beingstacked, as shown. However, in other aspects, the alignment pins 730 canbe inserted through the corresponding alignment holes 630 after theprimary and secondary replacement disk segments 612,712 are oriented inthe stacked configuration. According to example aspects, the alignmentholes 630 can be positioned on the replacement disk segments 612,712between the grooves 165 to avoid interruption of the fluid passageways175 formed therebetween and to ensure continuous contact of thereplacement disk segments 612,712 with the alignment pins 730.

FIG. 8 illustrates the assembled disk stack repair insert 800. Once thatprimary and secondary replacement disk segments 612,712, along with anyother replacement disk segments needed, have been stacked to replicatethe removable section 330 (shown in FIG. 3), each of the primary andsecondary replacement disk segments 612,712 can be coupled to theadjacent primary and secondary replacement disk segments 612,712 tosecure the primary and secondary replacement disk segments 612,712 inthe stacked configuration. For example, the primary and secondaryreplacement disk segments 612,712 segments can be joined together bywelding 820, as shown, or by any other suitable fastener, includingmechanical fasteners, such as bolts, screws, and the like. Moreover, inexample aspects, as shown, some or all of the primary and/or secondaryreplacement disk segments 612,712 can be coupled to the alignment pins730 passing through the corresponding alignment holes 630. For example,as shown in the present aspect, the primary and secondary replacementdisk segments 712 can be coupled to the alignment pins 730 by welding830, or any other suitable fastener. When the primary and secondaryreplacement disk segments 612,712 are stacked together and secured inthe stacked orientation, the primary and secondary replacement disksegments 612,712 can together define the disk stack repair insert 800.According to example aspects, the disk stack repair insert 800 candefine an arcuate inner insert surface 802 and an arcuate outer insertsurface 804, as shown. Fluid can be configured to flow through the fluidpassageways 175 (shown in FIG. 1) formed between the adjacentreplacement disk segments 612,712 from the inner insert surface 802 ofdisk stack repair insert 800 to the outer insert surface 804.

FIG. 9 illustrates the disk stack repair insert 800 partially insertedinto the insert opening 410 of the disk stack 100. According to exampleaspects, the size and shape of the disk stack repair insert 800 can besubstantially similar to the size and shape of the removable section 330(shown in FIG. 3), such that the disk stack repair insert 800 can fitsnugly and seamlessly within the insert opening 410. Moreover, as shown,the number of primary and secondary replacement disk segments 612,712combined (as well as additional replacement disk segments, if necessary)can correspond to the number of affected disks 240. According to exampleaspects, the upper replacement disk surface 512 of each replacement disksegment 612,712 can be configured to laterally align with the upper disksurface 212 of a corresponding one of the affected disks 240 to continuethe first groove pattern 620 uninterrupted. Furthermore, the lowerreplacement disk surface 714 of each replacement disk segment 612,712can be configured to laterally align with the lower disk surfaces 214 ofa corresponding one of the affected disks 240 to continue the secondgroove pattern 720 (shown in FIG. 7) uninterrupted. As such, with thedisk stack repair insert 800 positioned in the insert opening 410, thereplacement disk segments 612,712 can re-define the original fluidpassageways 175 (shown in FIG. 1A) of the disk stack 100 that wereinterrupted by the defect 230 (shown in FIG. 2) and by the removal ofthe removable section 330. For example, as shown, a lowermost one of thereplacement disk segments 612 a can be configured to laterally alignwith a lowermost one of the affected disks 240 a. As such, the lowerreplacement disk surface 714 of the lowermost replacement disk segment612 can confront the lower boundary wall 416 of the insert opening 410(e.g., the upper disk surface 212 of the uppermost original disk 110 c).Thus, the first groove pattern 620 of the uppermost original disk 110 ccan confront the second groove pattern of the lowermost replacement disksegment 612 a to re-define the original fluid pathways 175 therebetween.

Referring to FIG. 10, as described above, the inner circumference of theprimary replacement disk 510 (shown in FIG. 5) can be smaller than theinner circumference of the disk stack 100 and the outer circumference ofthe primary replacement disk 510 can be greater than the outercircumference of the disk stack 100. The secondary replacement disk 710can be substantially the same in size as the primary replacement disk510, and thus can also define an inner circumference and an outercircumference that can be smaller and larger, respectively, than theinner circumference and outer circumference of the disk stack 100. Assuch, according to example aspects, when the disk stack repair insert800 is fully received within the insert opening 410 (shown in FIG. 4),as illustrated, the inner insert surface 802 (shown in FIG. 8) of thedisk stack repair insert 800 can extend radially inward beyond the innersurface 160 of the disk stack 100, relative to the disk stack axis 152,and the outer insert surface 804 of the disk stack repair insert 800 canextend radially outward beyond the outer surface 170 of the disk stack100, relative to the disk stack axis 152.

As shown in FIGS. 11 and 12, the inner and outer insert surfaces 802,804of the disk stack repair insert 800 can then be machined down (forexample, sanded), such that the inner and outer circumferences of theprimary and secondary replacement disk segments 612,712 can match theinner and outer circumferences of the disk stack 100. As such, the diskstack repair insert 800 can be completely flush with the disk stack 100.Once machined to be flush with the disk stack 100, the disk stack repairinsert 800 can then be secured to the disk stack 100, for example, bywelding 1110, or by any other suitable fastening methods.

One should note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain embodiments include, while other embodiments donot include, certain features, elements and/or steps. Thus, suchconditional language is not generally intended to imply that features,elements and/or steps are in any way required for one or more particularembodiments or that one or more particular embodiments necessarilyinclude logic for deciding, with or without user input or prompting,whether these features, elements and/or steps are included or are to beperformed in any particular embodiment.

It should be emphasized that the above-described embodiments are merelypossible examples of implementations, merely set forth for a clearunderstanding of the principles of the present disclosure. Any processdescriptions or blocks in flow diagrams should be understood asrepresenting modules, segments, or portions of code which include one ormore executable instructions for implementing specific logical functionsor steps in the process, and alternate implementations are included inwhich functions may not be included or executed at all, may be executedout of order from that shown or discussed, including substantiallyconcurrently or in reverse order, depending on the functionalityinvolved, as would be understood by those reasonably skilled in the artof the present disclosure. Many variations and modifications may be madeto the above-described embodiment(s) without departing substantiallyfrom the spirit and principles of the present disclosure. Further, thescope of the present disclosure is intended to cover any and allcombinations and sub-combinations of all elements, features, and aspectsdiscussed above. All such modifications and variations are intended tobe included herein within the scope of the present disclosure, and allpossible claims to individual aspects or combinations of elements orsteps are intended to be supported by the present disclosure.

That which is claimed is:
 1. A method for repairing a disk stackcomprising: providing the disk stack comprising a plurality of originaldisks, each of the original disks defining a groove pattern, the diskstack defining a damaged region; removing the damaged region from thedisk stack to define an insert opening in the disk stack; providing adisk stack repair insert comprising a replacement disk segment; andinserting the disk stack repair insert into the insert opening to repairthe damaged region.
 2. The method of claim 1, wherein removing thedamaged region from the disk stack comprises cutting around the damagedregion to define a removable section and removing the removable sectionaway from the disk stack.
 3. The method of claim 2, wherein cuttingaround the damaged region to define the removable section comprisesdrilling around the damaged region with a drill.
 4. The method of claim3, wherein a cut formed around the removable section extends from anouter surface of the disk stack to an inner surface of the disk stack,the inner surface defining an inner bore of the disk stack.
 5. Themethod of claim 3, wherein the removable section defines a clearancearound the damaged region.
 6. The method of claim 1 wherein providingthe disk stack repair insert comprises stacking a first replacement disksegment with a second replacement disk segment, the first replacementdisk segment defining a first groove pattern and the second replacementdisc segment comprising a second groove pattern, the first groovepattern and the second groove pattern defining a first fluid passagewaytherebetween.
 7. The method of claim 6, wherein each of the first andsecond replacement disk segments defines an alignment hole, and whereinproviding the disk stack repair insert further comprises aligning thealignment holes and inserting an alignment pin through each of thealignment holes.
 8. The method of claim 7, wherein: the first groovepattern defines a plurality of first grooves; the second groove patterndefines a plurality of second grooves; and each of the first groovesconfronts and overlaps one or more of the second grooves.
 9. The methodof claim 8, wherein: the disk stack repair insert defines an innerinsert surface and an outer insert surface; fluid is configured to flowthrough the first fluid passageway from the inner insert surface to theouter insert surface; at least one of the first grooves of the firstreplacement disk segment is formed at the inner insert surface; and atleast one of the second grooves of the second replacement disk segmentis formed at the outer insert surface.
 10. The method of claim 9,further comprising sanding the outer insert surface and the inner insertsurface of the disk stack repair insert to be flush with an outersurface and an inner surface of the disk stack.
 11. The method of claim6, wherein: each of the first replacement disk segment and the secondreplacement disk segment defines a pair of opposing edges; the opposingedges of the first replacement disk segment do not intersect the firstgroove pattern; and the opposing edges of the second replacement disksegment do not intersect the second groove pattern.
 12. The method ofclaim 11, wherein: each of the opposing edges of the first replacementdisk segment are substantially linear and each of the opposing edges ofthe second replacement disk segment are substantially linear; a firstone of the opposing edges of the first replacement disk segment isaligned with a first one of the opposing edges of the second replacementdisk segment to define a substantially planar first side of the diskstack repair insert; and a second one of the opposing edges of the firstreplacement disk segment is aligned with a second one of the opposingedges of the second replacement disk segment to define a substantiallyplanar second side of the disk stack repair insert.
 13. The method ofclaim 12, wherein: the insert opening of the disk stack comprises afirst solid boundary sidewall and a second solid boundary sidewallopposite the first solid boundary sidewall; the substantially planarfirst side of the disk stack repair insert abuts the first solidboundary sidewall of the disk stack; and the substantially planar secondside of the disk stack repair insert abuts the second solid boundarysidewall of the disk stack.
 14. The method of claim 13, wherein the diskstack repair insert fits seamlessly within the insert opening, andwherein the method further comprises sealing the disk stack repairinsert with the disk stack by welding.
 15. The method of claim 6,wherein; the first replacement disk segment defines a third groovepattern opposite the first groove pattern; one of the original disks atleast partially defines the insert opening and defines a fourth groovepattern; and the third groove pattern and the fourth groove patterndefine a second fluid passageway therebetween.
 16. The method of claim15, wherein the third groove pattern is substantially the same as thesecond groove pattern, and wherein the fourth groove pattern issubstantially the same as the first groove pattern.